2000 Series Manual

Transcription

2000 Series Manual

OPERATION AND MAINTENANCE MANUAL
2000 SERIES GRANULATORS
CUMBERLAND ENGINEERING DIVISION
COPYRIGHT 2004 ALL RIGHTS RESERVED
REVISION 9/04 BJF
PART NO. CI044120
1
CUMBERLAND ENGINEERING
2900 S. 160th Street
NEW BERLIN, WI 53515 USA
TEL: 1-262-641-8600
FAX: 1-262-641-8653
PARTS AND SERVICE
TEL: 1-800-299-2919
FAX: 1-262-641-8615
MACHINE DATA
MODEL______________________________________
SERIAL NUMBER____________________________________
CUMBERLAND CUSTOMER ORDER NUMBER___________________________
REVISION 9/04 BJF
2
TABLE OF CONTENTS
TOPIC/SECTION
PAGE
INTRODUCTION……………………………………………………….xi
Factory address…
What is a granulator?……………………………………………………..xii
A granulator is…
The granulating of plastic…
The size of the granulate…
The disposal of plastic granulate…
SECTION 1 – SAFETY
Safety symbols and plates……………………...…………….………....1-1
Learn machine safety
Safety alert symbol
Understanding the signal words
Follow the safety instructions…………………………………………..1-2
Rotating knives safety plate
Warning – Pause after shutdown
Opening, guards, covers safety plate
Rotating machinery safety plate………………………………………..1-3
Opening hopper safety plate
Rotating knives safety plate
Warning shear hazard
Guard’s safety plate
Safety instruction plate………………………………………………….1-4
Hazardous voltage safety plate
Rotating knives safety plate………………………………………….…1-5
Motor rotation safety plate
Safety clothing and practices…………………………………………...1-6
Wear hearing protection
Wear safety glasses
Wear protective clothing………………………………………………..1-7
Keep your work area safe
Keep co-workers off the machine
Work safely……………………………………………………………..1-9
Be sure the rotor is motionless before opening machine
Safely clearing a jam……………………………………………………..……1-10
Work safely
Jackscrew operation
REVISION 9/04 BJF
3
Open the cutting chamber
Clear the jam……………………………………………………………1-11
Malfunction check
Restart the granulator
TABLE OF CONTENTS
TOPIC/SECTION
PAGE
SECTION 2- MACHINE PARTS AND CONTROLS ……………………………………..2-1
2000 Series granulator left front quarter view
2000 Series granulator, right front quarter view ……………………….……………...2-2
2000 Series granulator, machine open front view
2000 Series granulator, left rear quarter view…………………………………….…... 2-3
2000 Series granulator, right rear quarter view
SECTION 3 -INSTALLATION
Overview……………………………………………………………………………… 3-1
Machine weights
Uncrate the granulator
Move the granulator to its work site…………………………………………………...3-2
Allow adequate workspace
Level the granulator
Work safely
Remove the protective coating………………………………………………………...3-3
Check the knives and screens
Power considerations
Electrical wiring ………………………………………………………………………3-4
Work safely
Check for mechanical interferences………………………………………………….. 3-5
Set up the machine functions
Check rotation of motors
Reverse the motor rotation if needed
Interlock switch test procedure………………………………………………………. 3-6
Alternate test for the interlock switches
Lubrication………………………………………………………………………….…3-7
SECTION 4 -SETTINGS AND ADJUSTMENTS
Adjusting or replacing the bed knives………………………………………………... 4-1
Basic facts about the knives
Check all settings and adjustments before granulating any material
Malfunction check
Work safely
Open the cutting chambers interlock…………………………………..…….……...….4-2
Release the cutting chamber fasteners
Open the cutting chamber……………………………………………………………. 4-3
Care in handling knives
REVISION 9/04 BJF
4
Install the rotor-locating pin
TABLE OF CONTENTS
TOPIC/SECTION
PAGE
SECTION 4 -SETTINGS AND ADJUSTMENTS (Continued from previous page)
Adjusting or replacing the bed knives (Continued from previous page)
Loosen the mounting screws……………………………………………….4-4
Remove the first knife clamp or shield
Remove the bed knives
Clean the knife mounting surfaces…………………………………………4-5
Mounting screws
Replace the upstroke bed knife
Replace the upstroke knife clamp
Replace the down stroke bed knife…………………………………………4-6
Replace the down stroke knife shields
Check the bed knives
Gap adjustment tips.
Measure the knife gap……………………………………………………..4- 7
Set the down stroke knife shield
Check the knife gap
Tighten the screws to final torque…………………………………………4-8
Finalize installation of upstroke bed knife
Close the cutting chamber
Fasten the cutting chamber………………………………………………..4-9
Close the cutting chamber safety interlock
Adjusting or replacing rotor knives……………………………………. 4-10
Basic facts about the knives
Work safely
Open the cutting chamber interlock
Release the cutting chamber fasteners……………………………………4-11
Care in handling knives…………………………………………………..4-12
Lock the rotor
Remove the mounting screws
Remove the rotor knives
Clean parts for reassembly………………………………………………..4-13
Adjust the bed knives
Mounting screws
Install the new or reground rotor knives
Tighten the rotor knives to final torque…………………………………..4-14
Check the bed knives
Gap adjustment tips
REVISION 9/04 BJF
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TABLE OF CONTENTS
TOPIC /SECTION
PAGE
SECTION 4 SETTINGS AND ADJUSTMENTS (Continued from previous page)
Adjusting or replacing bed knives (Continued from previous page)
Measure the knife gap ………………………………………………...………4-14
Set the down stroke knife shield……………………………………………….4-15
Check the knife gap
Tighten screws for final torque
Close the cutting chamber……………………………………………………..4-16
Fasten the cutting chamber
Drive belt replacement and adjustment……………………………………………..4-17
Overview
Work safely
Remove the drive guard cover
Inspect the drive belts…………………………………………………………4-18
Remove the belts
Install the matched belts
Tighten the belt tension
Check the pulley alignment……….…………………………………………..4-19
Measure the belt span
Calculate the allowable belt deflection
Measure the deflection force
Compare the measured force to recommended force…………………………4-20
Adjust the belt tension
Tighten the motor base bolts
Replace the drive guard cover………………………………………………...4-21
Setting and adjusting the chamber jackscrew………………………………...4-22
REVISION 9/04 BJF
6
TABLE OF CONTENTS
TOPIC /SECTION
PAGE
SECTION 5 -OPERATION
Initial startup……………………………………………………………………………..5.1
Safety Check
Work safely
Check for mechanical interferences
Check the motor rotation direction……………………………………………...5-2
Run the motor
Discharge air adjustment
SECTION 5 -OPERATION
Normal operation………………………………………………………………………...5-4
Feed the machine
Shut down the machine
Discharge cleanout safety
SECTION 6 -MAINTENANCE
Periodic maintenance………………………………………………………...…6-1
Periodic Maintenance Schedule
Lubrication…………………………………………………………………...…6-2
Knife screw torque
Belt tension
Screen condition
In-feed flap condition……………………………………………………….…..6-3
Screen replacement……………………………………………………………..6-4
Work safely
Open the screen cradle interlock
Lower the screen cradle
Remove the discharge
Retract the screen cradle retainers
Beware of rotor knives
Remove the screen……………………………………………………………...6-5
Replace the screen
Raise the screen cradle
Close the screen cradle retainers
REVISION 9/04 BJF
7
TABLE OF CONTENTS
TOPIC/SECTION
PAGE
SECTION 6 -MAINTENANCE
Screen replacement (Continued from previous page)
Close the screen cradle interlock. ………………………………………………….6-6
Cutting chamber access …………...…………………………………………..6-7
Work safely
Open the cutting chamber interlock
Release the cutting chamber fasteners
Close the cutting chamber
Fasten the cutting chamber…………………………………………………………6-8
Knife sharpening..………….…………………………………………………...6-9
Rotor knife sharpening
Bed knife sharpening………………………………………………………………6-10
SECTION 7-TROUBLESHOOTING
Overview………………………...……….……………………………….….…….7-1
Test equipment
Locating trouble
Troubleshooting chart
Processing faults..…………………………………………………………..………7-2
Mechanical faults ………………………………………………………………….7-3
Electrical faults…………………………………………………………………….7-4
SECTI0N 8 -PARTS LISTS AND DRAWINGS
Recommended Spare Parts..………………………………………………………..8-1
Parts identification Cumberland Drawing no. C1044035….………………..8-2 to 8-6
Rotor positioning/Locking assembly………………………………………………8-7
Overall dimensions Cumberland Drawing no. CI044063, CI044122 and
CI044063-1………………………………………………………………….8-8 to 8-10
Wiring diagram Cumberland Drawing no………………………………………….8-11
REVISION 9/04 BJF
8
INTRODUCTION
THANK YOU for purchasing a CUMBERLAND 2000-SERIES GRANULATOR.
READ THIS MANUAL to learn how to operate and service your granulator safely. It covers the
family of granulators called the 2000 Series. This series of Cumberland Granulators is designed
for the big jobs in reclamation of thin-walled, injection-molded plastic parts, thermoforming
sheet, as well as film.
*NOTE: This manual covers light maintenance only. No further maintenance should be
performed without first contacting the Cumberland Service Department at the mailing address
and phone number shown below.
When calling the factory for service information or for parts, please have the model and serial
number of your machine on hand. The serial number is stamped on the plate mounted on center at
the back of the granulator just below the hopper.
ADDRESS, PHONE & FAX NUMBERS:
100 Roddy Avenue
South Attleboro. MA 02703-7951
Telephone: 508-399-6400
Fax number: 508-399-6653
REVISION 9/04 BJF
9
INTRODUCTION
WHAT IS A GRANULATOR?
A GRANULATOR is a machine that is designed to size-reduce plastic materials to chips, or
granulate. The machine can be fed either by hand through the hopper opening in the front or
automatically from a special hopper opening, which can be specially designed.
THE GRANULATING OF PLASTIC is achieved by the cutting action of sharp rotating
knives in close adjustment to one or more stationary knives called bed knives. The rotary knife
assembly is called a rotor. You will see many references to it as you read through this manual.
There are two bed knives in the machines covered by this manual. The heavy-duty rotor and bed
knife assemblies, combined with the screen (explained below) and their enclosing cutting
chamber are the heart of the granulator.
THE SIZE OF THE GRANULATE resulting from the cutting action described is controlled
by a screen, which fits tightly around the rotary knives in the cutting chamber. The screen retains
the plastic granulate until it is reduced to a small enough size to fall through the holes in the
screen. Screens with various diameter hole sizes are available for the granulator. The standard
screen hole size for the 2000-Series Granulators is 3/8" diameter. Screens are available with
either smaller or larger diameter hole sizes. For a given machine, the throughput capacity of the
granulator is dependent upon the size of the screen utilized.
DISPOSAL OF THE PLASTIC GRANULATE takes place after it passes through the
screen and drops into the discharge area, where it is removed from the machine by a discharge
blower and conveyed by air to a remote collection system. The blower can be mounted on either
side of the machine with its inlet located on the opposite side of the machine. The discharge
blower is available as optional equipment.
REVISION 9/04 BJF
10
SAFETY
SECTION 1-1
Safety Symbols & Plates
LEARN MACHINE SAFETY
Read this manual.
Learn how to operate the machine and how to
use the controls properly.
DO NOT ALLOW ANYONE TO OPERATE
THIS MACHINE WITHOUT PROPER INSTRUCTIONS.
THIS SAFETY alert symbol MEANS ATTENTION!
BE ALERT! YOUR SAFETY IS INVOLVED!
This symbol appears frequently in this manual
and on your machine. It is used to alert you to the
possibility of personal injury or death. Follow the
instructions in the safety messages identified with this symbol.
UNDERSTAND SIGNAL WORDS
A signal word such as – DANGER, WARNING or CAUTION, is always used with the safety alert symbol
to indicate the level of a potential hazard. These safety words are in accordance with ANSI Z535.5.
Danger! – Identifies the most serious hazard.
Disregard of this hazard will result in personal injury or
death. The signal word is printed over a red background.
Warning! – Identifies a hazard or unsafe practice.
Disregard of this hazard will result in severe personal
injury or death. The symbol is printed over an orange
background.
Caution! – Identifies a hazard or unsafe practice.
Disregard of this could result in minor personal injury or
product property damage. The signal word is printed over a
yellow background.
REVISION 9/04 BJF
11
SAFETY
SECTION 1-2
FOLLOW SAFETY INSTRUCTIONS:
Read all the safety messages in this manual and on your machine safety plates.
Follow the recommended precautions and safe
operating practices.
Keep safety plates in good condition.
Replace missing or damaged plates.
ROTATING KNIVES SAFETY PLATE (Located below the infeed opening at the front of the machine)
Do not, under any circumstances, place your hands into the feed opening beyond the curtain while the machine
is capable of running. Disconnect and lock out all power when it becomes necessary to work beyond this point. Make
sure the rotor has come to a full stop before reaching through the curtain.
WARNING -PAUSE AFTER SHUTDOWN (Located at the front of the cutting chamber) Pause, as suggested,
after shutting the machine down and locking out the power even though safety interlocks are in place to prevent injury.
Develop good safety habits by adhering to the messages on all the warning plates. The best safety provision is your
own careful concentration on safety.
OPENING HOPPER, GUARDS, COVERS SAFETY PLATE (Located on the screen cradle on the front
panel, left of the machine center.) The hopper, guards, and safety covers are in place for your protection during
machine operation. Be sure not to remove them until the rotor has come to a complete stop and you have disconnected
and locked out the power. Be sure to replace all guard before reconnecting power.
REVISION 9/04 BJF
12
SAFETY
SECTION 1-3
ROTATING MACHINERY SAFETY PLATE
(One located on the machine guard on the left side of the machine, one on the
screen cradle on the front panel, to the right of the machine center.)
Avoid personal injury by making sure that the rotor is stopped and the power is
disconnected and locked out before removing a machine guard. A motion
sensor monitors the rotor and disables the jackscrew motors if there is rotor
movement. If you see the rotor spinning after opening the machine,
immediately shut down and call for service.
OPENING HOPPER SAFETY PLATE
(Located on center at the lower, front side of the hopper)
Take the time for safety by disconnecting and locking out the
power before opening the hopper. Work carefully and beware of all hazards
with the hopper open and the knives exposed.
ROTATING KNIVES SAFETY PLATE (One located near the discharge
port and one located near the vent port on each side of the machine.)
Never reach into the vent or discharge areas without shutting down the machine
and locking out the power. Wear protective gloves whenever you work around
the rotor knives and do not open the access doors to them until you are certain
that the rotor has stopped and you have disconnected and locked out the power.
To clear a jam, refer to the topic entitled Safely Clearing a Jam later in this
section.
GUARDS SAFETY PLATE
(Located on the drive guard cover on the left side as you face the machine)
By keeping the guards in place at all times you are promoting good safety
practices and avoiding needless hazard and injury.
REVISION 9/04 BJF
13
SAFETY
SECTION 1-4
SAFETY INSTRUCTION PLATE
(Located on the front of the drive guard)
The safety instruction plate summarizes the most important safety
rules that you need to operate this machine safely.
Read it carefully and observe it always to promote safe machine
operation.
HAZARDOUS VOLTAGE SAFETY PLATE
(Located on the door of the jackscrew console)
Always call for the services of a licensed electrician when you think
that there is an electrical problem.
Never open any electrical panel if you are not a licensed electrician.
Touching the wrong terminals may result in serious injury or death.
REVISION 9/04 BJF
14
SAFETY
SECTION 1-5
ROTATING KNIVES SAFETY PLATE (One located on the front of
the cutting chamber and one on the front of the cradle)
The rotating knives are razor-sharp to the touch. Always verify that the rotor
is not moving. Avoid personal injury by making sure that the rotor is stopped
and the power is connected and locked out before opening the machine. A
motion sensor monitors the rotor and disables the jackscrew motors if there is
movement. If you see the rotor spinning after opening the machine,
immediately shut down the machine and call for service.
Wear protective gloves whenever you work around the rotor knives. To avoid
jamming your fingers between the rotor knives and the bed knives, refer to
the information for safely clearing a jammed cutting chamber later in this
section.
Ref. No. SPI-O30
MOTOR ROTATION SAFETY PLATE (Located on the door of the
jackscrew console) A REMINDER TO THE ELECTRICIAN to check the
motor rotation. It is important to check the motor rotation whenever electrical
connections to the motor are being made or have been disturbed for
maintenance. The wrong rotation direction can cause personal injury (by
throwing debris back toward the feed hopper opening) and/or by damaging
the knives.
*NOTE: The drive motor direction arrow plate is located on the top surface
of the drive guard toward the front of the machine.
REVISION 9/04 BJF
15
SAFETY
SECTION 1-6
Safety Clothing and Practices
(Located above the infeed opening at the front of the machine)
It is recommended that hearing protection be used at all
times when operating this equipment.
It is mandatory that hearing protection be worn when noise
exposure exceeds OSHA Standards Section 1910.95.
(Located above the infeed opening at the front of the machine)
Always wear proper eye protection when operating and/or
servicing this equipment.
Wear safety glasses with side shields or full-face safety
shields.
REVISION 9/04 BJF
16
SAFETY
SECTION 1-7
Safety Clothing & Practices
WEAR PROTECTIVE CLOTHING
Never wear neckties, dangling jewelry, loose-fitting clothing,
watches, bracelets, or rings.
Tie back long hair or restrain it with a hair net to ensure your
safety.
KEEP YOUR WORK AREA SAFE
Keep your work area clean and uncluttered.
Store your maintenance tools away from the granulator to prevent them from falling into the
machine and causing severe internal damage to the cutting chamber.
KEEP CO-WORKERS OFF THE MACHINE
Never lean or rest on the granulator.
Do not let co-workers lean on your machine while it is running. A moving part or shower of
material many cause unexpected injury.
REVISION 9/04 BJF
17
SAFETY
SECTION 1
Safety Clothing & Practices
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982
(Lockout/Tag-out of Energy Sources).
If it is not possible to lock out the power, have an electrician remove the fuses.
Make sure the rotor has come to a complete stop. Wear gloves to protect against injury from the rotor or
bed knives.
BE SURE THE ROTOR IS MOTIONLESS BEFORE OPENING MACHINE
Never open or remove any machine components unless the motor is electrically locked out and the rotor is
completely motionless.
REVISION 9/04 BJF
18
SAFETY
SECTION 1-10
Safely Cleaning A Jam
Make sure the rotor has come to a complete stop. Wear gloves to protect against injury
from the rotor or bed knives.
OPEN THE CUTTING CHAMBER
Open the screen cradle per instructions in Section 6 entitled Screen
Replacement.
Open the cutting chamber per instructions in Section 6 entitled Cutting
Chamber Access.
NEVER ATTEMPT TO FREE A JAMMED MACHINE BY PLACING YOUR
HANDS ON THE ROTOR, ON THE KNIVES, OR INSIDE THE CUTTING
CHAMBER.
KEEP YOUR HANDS CLEAR OF THE ROTATIONAL PATH OF THE
ROTOR KNIVES.
REVISION 9/04 BJF
19
SAFETY
SECTION 1-11
Safely Cleaning A Jam
CLEAR THE JAM
A leather mallet and block of wood of sufficient length to keep hands
away from the path of the knives can be used if required.
Use the block of wood to exert force on the rotor, usually in the
direction opposite normal rotation.
Make sure you have secure footing on a clean floor and keep your body
well braced while prying on the rotor. Guard against loss of balance should
the jammed condition suddenly come free.
Use pliers to remove material from the cutting chamber, keep in
mind that the removal of material may cause rotation of the rotor and
rotor knives.
If prying on the rotor is unsuccessful, remove the bed knife and the
rotor knife at the jam. For information about bed knives, refer to Section 4,
Settings and Adjustments.
Close the screen cradle per instructions in Section 6 entitled Screen
Replacement
Close the cutting chamber per instructions in Section 6 Cutting
Chamber Access.
A malfunction of the machine, such as a jam, may cause undue strain or damage to any part. Do not restart the
machine after such a malfunction without checking to see whether damage was done or whether settings were
changed by the malfunction.
RESTART THE GRANULATOR
If necessary to replace the fuses, call an electrician to do it. UNLOCK AND TURN ON the main
power.
Remove the OUT OF SERVICE tag, start the granulator by depressing the start pushbutton on the
electrical cabinet.
REVISION 9/04 BJF
20
MACHINE PARTS AND CONTROLS
SECTION 2-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Hold-down clamps - cutting chamber
Screen cradle retainers
Interlock actuator screw – cutting chamber
Safety plates
Feed hopper
Rotor bearing housing (Not shown)
Discharge duct (Optional mount to either side)
Start/Stop pushbuttons located on the electrical cabinet, not shown (Cabinet is option
equipment)
Hopper opening screw jack
Drive guard
Hopper flap
Rotor lock mechanism (Between guard and chamber)
The 2000 series granulators have a common cutting diameter of 20” (500mm) and a common
throat size of 20” (500mm) by widths ranging from up to 62” (1575mm). They are designed for
reclamation of large blow-molded and thin walled injection molded parts, films and fibers.
The machines in the 2000 Series can be fitted with screens having hole sizes to suit the particular
application. The 2000- Series machines conform to ANSI Standards: B151.11 and NFPA 79.
REVISION 9/04 BJF
21
SECTION 2-2
22000000 –– SSeerriieess G
Grraannuullaattoorr
p
e
n
M
a
c
h
i
n
e
O
Viieew
w
Machine Open FFrroonntt V
1.
Screen
2.
Rotor Knife
3.
Bed Knife (Down-stroke)
4.
Rotor locking mechanism
5.
Drive guard
6.
Flywheel guard (Optional)
REVISION 9/04 BJF
22
SECTION 2-3
22000000 –– sseerriieess G
Grraannuullaattoorr
LLeefftt R
e
a
r
Q
u
Rear Quaarrtteerr V
Viieew
w
1. Hopper jack screen
(50” & 62” wide machines will be equipped with an hydraulic system for opening the hopper)
2. Screen cradle gas spring
3. Screen cradle
4. Discharge chute
5. Discharge outlet pipe
REVISION 9/04 BJF
23
INSTALLATION
SECTION 3-1
OVERVIEW
This section deals with the procedures required to place your 2000 Series Granulator into
service after you receive it at your plant. The following basic steps need to be accomplished.
Uncrating the machine
Accounting for all necessary parts
Inspecting for damage and reporting any damage to the carrier
Cleaning the protective coating from the machine
Moving the machine to its service location
Checking and, if necessary, adjusting mechanical parts before applying electrical
power
Performing the start-up procedure
PLEASE FOLLOW THESE STEPS AS OUTLINED TO ACHIEVE A SAFE AND
SUCCESSFUL START UP OF YOU 2000 SERIES GRANULATOR.
The machine weights for the 2000 – Series Ganulators are as follows: 2042…….11,000 lbs.
2050…….12,750 lbs
2062…….14,500 lbs
UNCRATE THE GRANULATOR
As shipped, the granulator and the hopper are securely bolted onto separate skids and covered
with a wooden crate. The electrical cabinet, an optional item, is similarly packaged when
ordered.
Remove the strapping
Remove the packages and parts from the skid or inner sides of the crate
Remove the hold-down bolts, nuts, etc.
Inspect for damage during transit and notify the carrier immediately of any damage.
Check the packing list and notify Cumberland if there are any shortages.
REVISION 9/04 BJF
24
INSTALLATION
SECTION 3-2
MOVE THE GRANULATOR TO ITS WORK SITE
If lifting the machine is necessary, use appropriately rated lifting equipment. Always lift the unit from beneath
the base plate.
The machine WEIGHTS FOR THE 2OOO SERIES are as follows: 2042…….11,000 lbs.
2050…….12,750 lbs
2062…….14,500 lbs
LEVEL THE GRANULATOR
Once the granulator is at its final installation site, ensure that the machine is on a level surface and
resting firmly on its base-plate.
If necessary, use shims to level it.
It can be mounted on isolation pads or it can be lagged to the floor through holes provided in the base
plate.
ALLOW ADEQUATE WORK SPACE
Adequate clearance must be maintained so that all areas of the granulator are accessible and unobstructed for servicing,
maintaining, or operating the equipment. Space must be allowed for removing guards and screens.
Allow three feet (91 cm) on all sides of the machine for access.
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSIZ244:1-1982 (Lockout/Tag-out
of Energy Sources).
If it is not possible to lock out the power, have an electrician remove the fuses. .
Make sure the rotor has come to a complete stop.
(Continued on next page)
REVISION 9/04 BJF
25
INSTALLATION
SECTION 3-3
REMOVE THE PROTECTIVE COATING
The machine is shipped with a protective wax coating, which must be removed prior to start-up. The
coating can be removed with an acceptable solvent, such as mineral spirits.
Clean the following areas:
Inside the feed hopper
Inside the cutting chamber (knives, rotor, etc.)
Inside the discharge area.
CHECK THE KNIVES AND SCREENS
Be sure that the screens are properly installed into the cutting chamber and that nothing has fallen into the
cutting chamber during transportation and/or installation. Refer to Section 6, Maintenance, for the
procedure entitled Screen Replacement and Cutting Chamber Access.
Check to be sure the bed knife and rotor knife hold-down screws are tight and knife clearances are correct. Refer to Section 4, Settings and Adjustments.
POWER CONSIDERATIONS
Before operating the granulator, it is extremely important that a licensed electrician correctly wires the
machine into the plant power source. See Section 8, for wiring diagram.
All electrical equipment must be properly grounded in accordance with local and national codes to
protect personnel from electrical shock.
A fusible, lockable disconnect between the plant power source and the machine electrical cabinet
is highly recommended.
REVISION 9/04 BJF
26
INSTALLATION
SECTION 3-4
ELECTRICAL WIRING
To wire the granulator, run power (of proper voltage) from the plant source through a lockable, fusible
disconnect to the machine electrical control panel.
50” & 62” machines are equipped with a hydraulic system for opening the hopper.
To wire the hydraulic controls, run power (of proper voltage) from the plant source through a lockable, fusible
disconnect to the machine-mounted control panel.
From the main electrical panel, make the necessary wiring connections to the main drive motor and any
auxiliary motors or control connections.
Refer to the diagram appended to this manual for wiring connections for typical machine applications,
Check the wiring diagram supplied for any wiring that is specific to you application. This diagram is part of the
documentation shipped with the machine.
After power is connected, do not make any adjustments to the machine without performing the
following operations.
TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 or ANSI Z244.1-1982
If you cannot lock out power, have an electrician remove the fuses.
Tag the machine as OUT OF SERVICE.
Wear gloves to protect against injury from the rotor or bed knives.
REVISION 9/04 BJF
27
INSTALLATION
SECTION 3-5
CHECK FOR MECHANICAL INTERFERENCES
TURN POWER OFF and LOCK IT OUT per OSHA 1910.147 OR ANSI Z244.1-1982
(Lock-out/Tag-out of Energy Sources).
Open the cutting chamber. Refer to the procedures entitled Screen Replacement and Cutting Chamber
Access in Section 6.
Turn the rotor slowly with gloved hands, at least one full revolution, to verify that there are no
interferences between the rotor knives and bed knives and/or with the screen.
SET UP THE MACHINE FUNCTIONS
Set and torque the rotor knives and bed knives as shown in Section 4, Settings and Adjustments.
Adjust the V-belt drive per the procedure in Section 4 entitled Drive Belt Replacement or Adjustment.
CHECK ROTATION OF MOTORS
With the cutting chamber closed, jog the drive motor by pushing the start and stop buttons in quick
succession. This starts and stops the granulator motor. Be alert for mechanical interferences between parts.
Stop the machine immediately if you hear unexpected sounds.
Jog the motor to check the rotational direction. The V-belt sheave must rotate in the direction shown
by the arrow located on top of the belt guard. Have a helper confirm the direction by looking at the V-belt
/pulley through the viewing window on the side of the belt guard cover.
If your unit has the optional discharge blower located on either the right or left side of the machine,
check the direction of rotation of the blower.
IF NECESSARY, REVERSE THE MOTOR ROTATION
It is extremely important that a licensed electrician performs these steps.
If any motor rotates in the wrong direction, stop the machine by depressing the stop button.
TURN OFF AND LOCK OUT the power at the disconnect switch which supplies power to the main
electrical control panel per OSHA 1910.147 OR ANSI Z244.1-1982 (Lock-out/Tag-out of Energy Sources).
If the disconnect is not lockable, remove the fuses.
REVISION 9/04 BJF
28
INSTALLATION
SECTION 3-6
IF NECESSARY, REVERSE THE MOTOR ROTATION
WARNING!
With all power to the electrical control panel disconnected and locked out, reverse any two of the three
power line conductors to the machine. If there is more than one motor on the machine, and one is turning
in the wrong direction, and one isn't: reverse any two of the three line conductors at the overload relay of
the motor that you wish to reverse.
Unlock the power and switch it on at the electrical disconnect (if necessary, replace the fuses).
Re-check the rotation direction of the motor(s).
INTERLOCK SWITCH TEST PROCEDURE
With the machine stopped, perform the following steps:
TURN OFF and LOCK OUT THE POWER per OSHA 1910.147 OR ANSI Z244.1-1982
(Lock-out/ Tag-out of Energy Sources).
Use the wiring diagram appended to this manual to locate the interlock switch terminal strip in the
junction box control panel.
The wires for the upper chamber interlock switch are numbers 1 and 16.
The wires for the screen cradle interlock switch are numbers 16 and 5.
Connect an ohmmeter across each interlock switch terminal or across all interlock switch terminals
(wire numbers 1 and 5).
Switch the ohmmeter resistance to the lowest scale. When the interlock actuator screws are in place
and properly activating their switches, the ohmmeter should read zero resistance.
When either or both actuator bolts are withdrawn, the ohmmeter should read infinite resistance.
Loosen ONE actuator screw 3 to 4 turns. If, the meter reads INFINITY, before the screw can be
completely removed, the INTERLOCK IS WORKING. If the meter reads ZERO RESISTANCE, when
the actuator screw is completely REMOVED, the INTERLOCK IS NOT WORKING.
REPLACE THE FIRST ACTUATOR SCREW TESTED BEFORE TESTING THE SECOND
ONE.
If an interlock does not work, the complete mechanism, including the switch, must be removed and
disassembled to determine the cause of the malfunction.
ALTERNATE TEST FOR THE INTERLOCK SWITCHES
With the cutting chamber and screen cradle closed and power on perform the following steps:
Push the start button to start the granulator.
Retract the screen cradle interlock actuator screw by turning it counterclockwise.
The granulator should stop after several turns.
If the machine continues to run, TURN OFF AND LOCK OUT THE POWER per
OSHA 1910.147 OR ANSI Z244.1-1982 (Lock-out/tag-out of Energy Sources).
Have the electrician check the interlock switch on the screen cradle to correct the malfunction.
REVISION 9/04 BJF
29
INSTALLATION
SECTION 3-6
ALTERNATE TEST FOR THE INTEROCK SWITCHES
(Continued from previous page)
After the test or repair, engage the screen cradle interlock actuator screw.
If necessary, unlock and turn on the power.
Push the start button to start the granulator.
Retract the cutting chamber interlock actuator screw by turning it counterclockwise. The granulator
should stop after several turns.
If the machine continues to run, TURN OFF AND LOCK THE POWER per
OSHA 1910.147 or ANSI Z244.1-1982 (Lock-out/Tag-out of energy sources).
Have an electrician check the interlock switch on the cutting chamber to correct the malfunction.
After the test or repair, if necessary, engage the cutting chamber interlock actuator screw.
TEST THE ZERO SENSOR (Optional) - STANDARD with 50” & 62” Wide Machine
Depress the button to start the granulator.
When the machine reaches full speed, depress the stop button to stop the granulator.
Release the cutting chamber hold-down clamps using the procedures in Section 6 entitled Cutting
Chamber Access.
While the rotor is still turning, actuate the hopper opening hydraulic system console by turning the
CC/Hopper selector switch to the RAISE position.
The hydraulic system should not operate until the rotor has come to a complete stop.
If the hydraulic system operates before the rotor stops, TURN OFF AND LOCKOUT THE
POWER per OHSA 1910.147 or ANSI Z244.1-1982 (Lock-out/Tag-out Energy Sources).
Have a mechanic and electrician check the speed sensor.
LUBRICATION
The machine is pre-lubricated except for the motor. For motor lubrication, check the tag supplied by the
motor manufacturer.
After the 2000-Series Granulator has been in service for some time, the main bearings should be periodically
lubricated. Refer to Section 6, Maintenance, for further information.
REVISION 9/04 BJF
30
SETTINGS AND ADJUSTMENTS
SECTION 4-1
Adjusting or Replacing Bed Knives
BASIC FACTS ABOUT THE KNIVES
All of the rotor knives are ground in sets to equal dimensions. Mount and service them as sets.
The rotor knives must be mounted tightly against the backs of the knife seats in order to make it
possible to achieve consistent knife clearances.
Accurate cutting clearance is obtained by setting the bed knives to a 0.006 in. to 0.008 in.
(0.15mm to O.20m) gap from the rotor knives.
The bed knives are adjusted by turning the PUSH screws. For best results, start with the bed
knives adjusted to a wide gap from the rotor knife and slowly adjust them to the required gap by
turning the PUSH screws in the same direction.
CHECK ALL SETTINGS AND ADJUSTMENTS BEFORE GRANULATING ANY
MATERIAL
Proper adjustments and settings are made prior to shipment, however the machine may require
readjustment. The standard knife gap setting is between six and eight thousandths of an inch (0.006 in. to
0.008 in. or 0.15 mm to 0.20 mm).
NOTE: These instructions apply to both the upstroke (the bed knife furthest from you when you service
the cutting chamber) and the down-stroke bed knives.
WORK SAFELY
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources).
MALFUNCTION CHECK
A malfunction of the machine, such as a jam, may cause undue strain or damage to any part. Do not restart
the machine after such a malfunction without checking to see whether damage was done or whether
settings were changed by the malfunction.
REVISION 9/04 BJF
31
SECTION 4-2
INTERLOCK
Disengage the interlock actuator screw with
a box wrench or a ratchet wrench.
Make sure the end of the interlock actuator
screw is visible and clear of any contact.
When disengaged, the interlock opens the
electrical control circuit to the motor and
prevents the machine from running.
RELEASE THE CUTTING CHAMBER FASTENERS
Turn the hold-down clamps counterclockwise to loosen them.
Swing the hold-down clamps toward you until they are disengaged from the cutting chamber
housing.
REVISION 9/04 BJF
32
SECTION 4-3
The Jackscrew, which opens the machine, should never be operated until the rotor is completely
stopped.
Make sure that no one is near the Jackscrew or the hopper during operation.
Turn the Jackscrew crank handle until the hopper opens sufficiently to allow access to
the cutting chamber and the weight of the hopper is over the pivot center.
NOTE: 50” and 62” machines are equipped with a hydraulic system to open the machine.
CARE IN HANDLING KNIVES
The rotor knives and bed knives are very sharp. Wear heavy gloves to avoid injury.
Use the rotor lock mechanism to lock the rotor into position that is least likely to cause injury
while you work. The mechanism will keep the rotor from turning. A block of wood wedged
around the rotor, can also be used to lock the rotor in place.
If the rotor knives and bed knives are to be removed, remove the rotor knives first (and then
replace them last) to reduce the chance of injury.
ENGAGE THE ROTOR LOCK MECHANISM
Locate the rotor lock mechanism on the left side of the
granulator, between the belt guard and the bearing housing.
Pull the locking pin & rotate the plunger until it comes in
contact with the flywheel locking the rotor position.
Re-install the pin to maintain locked position.
REVISION 9/04 BJF
33
SECTION 4-4
LOOSEN THE MOUNTING SCREWS
Select either the upstroke knife or the downstroke knife for first
removal.
Loosen the bed knife screws with a 30 mm socket mounted on a
breaker bar. These screws are tightened to a torque of 472 ft lbs (640
Nm) so make sure you have the proper breaker bar (a four foot long
(1.2 m) bar with a 3/4 inch (19 mm) drive is suggested). Make sure you
have solid footing while you apply the breaking force.
REMOVE THE FIRST KNIFE CLAMP OR SHIELD
Remove the screws on one half of the selected bed knife using a
30mm socket or equivalent wrench.
*NOTE: When removing the knife clamp on the upstroke knife (the similar
piece on the down-stroke knife is called knife shield), hold the clamp while
removing the last screw to keep it from slipping off its inclined mounting
surface. The knives will not slip off because the captive adjusting screws
secures them.
Keep the screws for reinstallation or use new factory-supplied
screws of the same specification for replacement.
Repeat the removal procedure for the remaining knife clamps and
shields.
REMOVE THE BED KNIVES
Remove the bed knives by lifting each half until the knife clears the
push screw and block.
Remove the second bed knife using the same procedure.
REVISION 9/04 BJF
34
SECTION 4-5
CLEAN THE KNIFE MOUNTING SURFACES
Clean the knife mounting surfaces with a stone or
other non-marring tool and wipe them with a clean cloth.
Make sure they are free of all material, dust, and dirt.
MOUNTING SCREWS
DANGER!
DO NOT REPLACE THE MOUNTING SCREWS WITH ANY TYPE OF SCREW OTHER THAN
THAT SPECIFIED BY CUMBERLAND.
Substitution of improper screws could lead to premature failure, equipment damage, and serious injury to
personnel.
When regrinding the knives: you may re-use the same screws and washers, but do not re-use them more
than six times. When installing new knives, replace the screws and washers with those furnished by the
factory.
REPLACE THE UPSTROKE BED KNIFE
Wipe the screws with a lightly oiled cloth; do not
leave an oil film since lubrication can adversely affect the
stress on a screw installed to a fixed torque.
Install the upstroke knife making sure to install it
with the knife-edge on the lower side.
Back off the bed knife push screws at the rear of the
knife.
Repeat these steps for the second half of the knife.
REPLACE THE UPSTROKE KNIFE CLAMP
Place the clamp over one half of the knife and hold it in
position until you fasten the first two screws and washers fingertight.
Place the second clamp over the second half of the knife and
hold it while you fasten it.
Install the remaining mounting screws and washers and
tighten them finger-tight.
REVISION 9/04 BJF
35
SECTION 4-6
REPLACE THE DOWNSTROKE BED KNIFE
Install the down-stroke bed knife (located on the
near side of the rotor) making sure to install it with the
knife-edge on the upper side.
Back off the bed knife push screws at the rear of
the knife.
Repeat these steps for the second half of the downstroke knife.
REPLACE THE DOWNSTROKE KNIFE
SHEILDS
Place the shields over the bed knife.
Install the mounting screws and washers and
tighten them finger-tight.
CHECK THE BED KNIVES
Check both halves of the upstroke knife (the bed knife on the far side of the rotor) to be
sure that the cutting edges face down.
Check both halves of the down-stroke knife (the bed knife on the near side of the rotor) to
be sure that the cutting edges face up.
GAP ADJUSTMENT TIPS
It is best to keep the adjustments on the bed knife push screws moving in the same
direction. This eliminates the effect of backlash in the adjusting screw.
Make the screw adjustments in small steps to keep the bed knife adjustment even over the
width of the machine.
To avoid cutting the shim stock, turn the rotor backward during the adjustment procedure.
Use the rotor knife with the largest dimension from rotor centerline as the reference, i.e.,
the highest knife.
REVISION 9/04 BJF
36
SECTION 4-7
MEASURE THE KNIFE GAP
If you are changing the rotor knives, do so now, otherwise
continue with this procedure.
Use brass shim stock to set the knife gap to the cutting
clearance of 0.006 in. to 0.008 in. (0.15 mm to 0.20 mm).
Remove the rotor-locating pin. (See page 4.3)
Rotate the rotor backward, by hand, and measure the
gap between it and the bed knife at the point of shear. You
can work on each half of the bed knife independent of the
other half but keep them in step with each other by working
from side-to-side.
SET THE DOWNS1ROKE KNIFE SHIELD
Position the knife-shield so that it sets back from the
bed knife-edge about 1/32 in. for film and 1/16 in. for
thicker materials. Use a plastic or leather mallet, if
necessary, to tap the shield or knife.
The upstroke knife clamp does not need this
adjustment, and snug down the mounting screws with a 30
mm socket wrench.
Carefully adjust the bed knife clearance to its final
setting.
CHECK THE KNIFE GAP
Snug the screws down in stages keeping them about even as you progressively tighten them.
Recheck the knife gap after snugging down the mounting screws. )
After setting up to one rotor knife (usually the highest knife), rotate the remaining knives
slowly by the bed knife and quickly verify the knife gap.
REVISION 9/04 BJF
37
SECTION 4-8
TIGHTEN THE SCREWS TO FINAL TORQUE
When the knife gap is adjusted to the proper dimension, tighten
the mounting screws to a torque of 472 ft lbs (640 Nm). For safety,
make sure that you have solid footing when you apply this final
torque.
Recheck the gap after tightening the screws to the final torque.
Make sure that both halves of the bed knife are adjusted.
FINALIZE INSTALLATION OF UPSTROKE BED KNIFE
To complete the installation of the upstroke bed knife, use the same
procedures as for the down-stroke knife. The titles follow:
Measure the knife gap.
Unlike the knife shield, the knife clamp does not need to be adjusted.
Check the knife gap.
Tighten the screws to final torque.
CLOSE THE CUTTING CHAMBER
WARNING!
Make sure there is no one near the Jackscrew or Hopper.
Clear the mating surfaces of the cutting chamber of any debris
that might prevent tight closer.
Check the rotor locking mechanism and back out the plunger if
necessary.
At the jackscrew, turn the crank handle till the hopper stops.
On 50” and 62” machines, activate the hydraulic system to
close the hopper.
REVISION 9/04 BJF
38
SECTION 4-9
FASTEN THE CUTTING CHAMBER
Raise the hold-down clamps to their
upright positions
Turn the knobs clockwise until they are
tight against the chamber housing.
CLOSE THE CUTTING CHAMBER SAFETY INTERLOCK
Engage the safety interlock by turning the actuator screw clockwise with a box wrench or a ratchet
wrench
Make sure the screw is fully seated against the surface of its housing.
When engaged, the interlock closes the electrical control circuit to the motor and allows the machine to run.
If necessary to replace the fuses, call an electrician to do it.
UNLOCK AND TURN ON the main power.
Remove the OUT OF SERVICE tag.
Be sure the rotor lock mechanism is not engaged.
Start the granulator by depressing the start pushbutton on the electrical cabinet.
REVISION 9/04 BJF
39
SECTION 4-10
Adjusting or Replacing Rotor Knives
BASIC FACTS ABOUT THE KNIVES
All of the rotor knives are ground in sets to equal dimensions. Mount and service them as sets.
The rotor knives must be mounted tightly against the backs of the knife seats in order to make it possible to
achieve consistent knife clearance.
Accurate cutting clearance is obtained by setting the bed knives to a 0.006 in. to 0.008 in. (0.15mm to
0.20mm) gap from the rotor knives.
The knives are adjusted by turning captive adjusting screws. For best results, start with the bed knives adjusted
to a wide gap from the rotor knife, and slowly adjust them to the required gap by turning the screws in the
same direction; avoid reversals. Reversals introduce inaccuracies due to backlash.
WORK SAFELY
WARNING!
(Lock-out/Tag-out of Energy Sources).
INTERLOCK
Disengage the interlock actuator screw with a
box wrench or a ratchet wrench.
When disengaged, the interlock opens the electrical
control circuit to the motor and prevents the machine
from running.
REVISION 9/04 BJF
40
SECTION 4-11
Swing the hold-down clamps toward you until they are disengaged from the cutting chamber
housing.
The jackscrew, which opens the machine, should never be operated
until the rotor is completely stopped.
Make sure no one is near the jackscrew or the hopper
during operation.
Turn the jackscrew crank handle until the hopper opens
sufficiently to allow access to the cutting chamber and the
weight of the hopper is over the pivot center.
*NOTE: 50” and 62” machines are equipped with a hydraulic
system to open the hopper.
REVISION 9/04 BJF
41
SECTION 4-12
CARE IN HANLDING KNIVES
WARNING!
The rotor knives and bed knives are very sharp; therefore, it is imperative that you wear a pair of
heavy gloves to avoid injury.
Use the rotor locking mechanism to lock the rotor in the least likely position to cause you injury while you
work. The locking mechanism keeps the rotor from turning. A block of wood wedged around the rotor can
also be used to lock to rotor in place. If the rotor knives and bed knives are to be removed, remove the rotor
knives first and replace them last to reduce the chance of injury.
LOCK THE ROTOR
Locate the rotor lock mechanism on the left side of the
granulator, between the belt guard and bearing housing.
Pull the locking pin and rotate the plunger until it comes
in contact with the flywheel, locking the rotor position.
Re-install the pin to maintain locked position.
REMOVE THE MOUNTING SCREWS
Loosen the rotor knife screws with a 30 mm socket
mounted on a breaker bar (These screws are tightened to a
torque of 472 ft lbs (640 Nm) so make sure you have the
proper breaker bar (a four foot long (1.2 m) bar with a 3/4
inch (19 mm) drive is suggested. Make sure you have solid
footing while you apply the breaking force.
Remove the mounting screws from the right rotor knife
with a suitable socket wrench.
REMOVE THE ROTOR KNIVES
Lift the right knife off from the rotor and repeat the process with the left rotor knife.
Remove the rotor-locating pin, turn the rotor to bring the next knives into position for removal,
insert the locating pin to hold the rotor in this position. Repeat the process for the remaining
knives.
REVISION 9/04 BJF
42
SECTION 4-13
CLEAN PARTS FOR REASSEMBLY
Clean the rotor knife seats with a stone or other nonmarring tool. Make sure that the backs of the knife seats are
clean so that the rotor knife can be placed squarely against
them.
Wipe the screws with lightly oiled cloth, do not leave an oil
film since lubrication can adversely affect the stress on a
screw installed to a fixed torque value.
ADJUST THE BED KNIVES
If the bed knives are installed, make sure that they are set back a sufficient amount to avoid
interference with the new or reground rotor knives.
MOUNTING SCREWS
DO NOT REPLACE THE MOUNTING SCREWS WITH ANY TYPE OF SCREW OTHER
THAN THAT SPECIFIED BY CUMBERLAND.
Substitution of improper screws could lead to premature failure, equipment damage, and serious injury
to personnel.
When regrinding the knives, you may re-use the same screws and washers but do not re-use them
more than six times. When installing new knives, replace the screws and washers with those furnished
by the factory.
INSTALL THE NEW OR REGROUND ROTOR
KNIVES
Engage the rotor lock mechanism.
Place the first half rotor knife onto the rotor with the
beveled edge facing up and toward you This leaves the backside of the knife sitting squarely against the back of the knife
seat on the rotor.
Center the knife mounting holes over the rotor mounting
holes and install the screws. Tighten the screws finger- tight
while holding the knife snug against the back of the knife
seat.
REVISION 9/04 BJF
43
SECTION 4-14
TIGHTEN THE ROTOR KNIVES TO FINAL TORQUE
Use a 30rnm socket wrench to tighten the mounting screws on
each knife in small steps keeping them about even as you increase
the torque on them.
Use a torque wrench to apply the final torque of 472 ft lbs (640
Nm) to the mounting screws. Make sure your footing is secure
before you apply the final torque.
Check with a 0.0015" (0.04 mm) feeler gage to ensure that each
knife is snug against the knife seat.
CHECK THE BED KNIVES
If the bed knives have been removed, check them as follows:
Check both halves of the upstroke knife (the bed knife on the far side of the rotor) to be sure that the
cutting edges face down.
Check both halves of the down-stroke knife (the bed knife on the near side of the rotor) to be sure that
the cutting edges face up.
GAP ADJUSTMENT TIPS
It is best to keep the adjustments on the bed knife push screws moving in the same direction. This
eliminates the effect of backlash in the adjusting screw.
Make the screw adjustments in small steps to keep the bed knife adjustment even over the width of the
machine.
To avoid cutting the shim stock, turn the rotor backward during the adjustment procedure.
Use the rotor knife with the largest dimension from rotor centerline as the reference, i.e., the highest
knife.
MEASURE THE KNIFE GAP
Use brass shim stock to set the knife gap to the cutting clearance of
0:006 in. to 0.008 in. (0.15 mm to 0.20 mm).
Remove the rotor-locating pin, and back out the plunger.
Rotate the rotor backward, by hand, and measure the gap between it
and the bed knife at the point of shear. You can work on each half of the
bed knife independent of the other half but keep them in step with each
other by working from side-to-side.
REVISION 9/04 BJF
44
SECTION 4-15
SET THE DOWNSTROKE KNIFE SHIELD
Position the knife-shield so that it sets back from the bed knifeedge about 1/32 in. for film and 1/16 in. for thicker materials. Use a
plastic or leather mallet, if necessary, to tap the shield or knife.
The upstroke knife clamp does not need this adjustment.
Carefully adjust the bed knife clearance to its final setting and
snug down the mounting screws with a 30 mm socket wrench.
CHECK THE KNIFE GAP
Snug the screws down in stages keeping them about even as you
progressively tighten them. Recheck the knife gap after snugging
down the mounting screws.
After setting up to one rotor knife (usually the highest knife),
rotate the remaining knives slowly by the bed knife and quickly
verify the knife gap.
TIGHTEN THE SCREWS TO FINAL TORQUE
When the knife gap is adjusted to the proper dimension, tighten
the mounting screws to a torque of 472 ft pounds (640 Nm). For
safety, make sure that you have solid footing when you apply this
final torque.
Recheck the gap after tightening the screws to the final torque.
Make sure that both halves of the bed knife are adjusted.
REVISION 9/04 BJF
45
SECTION 4-16
Make sure that no one is near the hopper.
Clear the mating surfaces of the cutting chamber of and debris
that might prevent closure.
REMOVE THE ROTOR LOCKING PIN and back out the
plunger, turn the handle until the hopper stops.
Do not continue to turn the crank after the hopper has stopped.
On 50” and 62” machines, activate the hydraulic system to close
the hopper.
Raise the hold-down clamps to their upright positions.
Turn the knobs clockwise until they are tight against the chamber housing.
wrench.
When engaged, the interlock closes the electrical control circuit of the motor and allows the machine to run.
Be sure the rotor locking mechanism is not engaged.
REVISION 9/04 BJF
46
SECTION 4-17
Drive Belt Replacement Or Adjustment
OVERVIEW
Belt tension is important to the proper operation of the drive system of your granulator.
Improper belt tension can lead to excessive belt wear and/or undue bearing wear on the
rotor and motor bearings.
This procedure shows you how to access the drive belts and how to adjust the tension to
recommended levels. It also shows you how to replace the belts.
WORK SAFELY
REMOVE THE DRIVE GUARD COVER
Use a socket wrench to remove the fasteners that retain the
drive guard cover.
Remove the cover.
REVISION 9/04 BJF
47
SECTION 4-18
INSPECT THE DRIVE BELTS
Check the belts for cracks in the V-sections that ride in the pulley grooves as well as on the
outside surface of the belts. Also look for signs of excessive wear.
If replacement is necessary, continue with the steps that follow.
If it is not necessary to replace the belts, skip ahead to the step entitled Measure the Belt
Span.
REMOVE THE BELTS
Loosen the motor mount locking screws.
Loosen the belt tension on the V-belts by turning the adjusting
screws on the motor base counterclockwise.
When the tension has been released sufficiently, slip the belts
over the pulley and remove them.
If replacement of any V-belt is necessary, all belts must be
replaced at the same time with a set of matched belts.
INSTALL THE MATCHED BELTS
Check the parts list to verify the part number of the correct
belts.
Slip the belts into the grooves, one-at-a-time, making sure that
the motor base has been adjusted enough to allow the belts to be
installed without danger of overstressing them by forcing them over
the edges of the V-grooves.
TIGHTEN THE BELT TENSION
Turn the adjusting screw on the adjustable motor base
clockwise to increase the distance of the motor shaft from the rotor
sheave. When the belts become snug, but not tight, stop the
adjustment and use the procedure that follows to set the belt
tension.
REVISION 9/04 BJF
48
SECTION 4-19
CHECK THE PULLEY ALIGNMENT
Tug outward on the pulleys to verify that they are tight on their
shafts.
Check the pulley alignment by holding a straight edge against the
edge of the large pulley and verifying that it is aligned with the edge of
the small pulley. If the edges of the pulleys do not align, perhaps
because the small pulley doesn't have as many grooves, use a tape to
measure from the straight edge to the belt on each pulley.
MEASURE THE BELT SPAN
Measure the belt span between the contact points on the large and
small pulleys as shown.
CALCULATE THE ALLOWABLE BELT DEFLECTION
The allowable belt deflection is obtained as follows.
Allowable belt deflection =Belt Span in inches (or mm) divided by 64
Another way to show that relationship: allowable belt deflection = Belt Span (in inches or mm)
64
MEASURE THE DEFLECTION FORCE
A gage to measure belt tension greatly facilitates this measurement.
You may purchase one from Cumberland Engineering, or from the belt
manufacturer.
Use the belt gage to measure the force required to deflect the belt to
the allowable dimension.
*NOTE: Check the instructions supplied with the belt tension gage for
proper setting of the scales.
REVISION 9/04 BJF
49
SECTION 4-20
COMPARE MEASURED FORCE TO RECOMMENDED
FORCE
Compare the deflection force measured, to the value shown in
the table.
For new belts the value for run-in should be used.
For belts, which have been running two days or more, use the
values for normal running.
ADJUST THE BELT TENSION
Adjust the sliding motor base to increase the belt tension by turning the
adjusting screws clockwise.
When the tension has been increased significantly, recheck it using the
procedure just described.
Repeat the process of adjustment and tension checks until the allowable
deflection is achieved while the deflection force is within the range shown
in the table.
Tension new drives at the maximum deflection force recommended.
Check the tension at least two times during the first two days of
operation. There is normally a rapid decrease in tension until the belts are
run inCheck the tension periodically after the first day of operation and keep
the tension in the recommended range.
The correct operating tension for a V-belt drive is the lowest tension
that allows NO belt slip under peak load conditions.
If the deflection is more than the specified deflection at the recommended
force, tighten the belts. If the deflection is less than the specified deflection
at the recommended force, loosen the belts.
TIGHTEN THE MOTOR BASE BOLTS
Tighten down the motor mounting bolts.
REVISION 9/04 BJF
50
SECTION 4-21
REPLACE THE DRIVE GUARD COVER
Replace the guard cover.
Use a socket wrench to replace the fasteners.
REVISION 9/04 BJF
51
SECTION 4-22
Setting The Chamber Jackscrew
WORK SAFELY
TURN OFF AND LOCKOUT the power per OSHA 1910.147 OR ANSI Z244.11982 (Lockout/Tag-out of Energy Sources).
OPEN THE CUTTING CHAMBER INTERLOCK
Disengage the interlock actuator screw with a box wrench or a ratchet wrench.
Make sure the end of the interlock actuator screw is visible and clear of any contact.
When disengaged, the interlock opens the electrical control circuit to the motor and
REVISION 9/04 BJF
52
OPERATION
SECTION 5-1
Initial Startup
SAFETY CHECK
Before operating the granulator, make sure that all of the electrical, mechanical, and lubrication
requirements have been completed in accordance with the installation instructions in Section 3.
Proper adjustments and settings are made prior to shipment, however the machine may require
readjustment. For knife gap settings refer to Section 4, Settings and Adjustments.
If the machine is being started for the first time or if it has been moved to a new location, perform
the following check to ensure a safe startup.
WORK SAFELY
Wear safety gloves to protect against injury from the rotor and bed knives.
CHECK FOR MECHANICAL INTERFERENCES
Remove the drive guard cover by removing the fasteners with a socket wrench then
remove the cover.
Turn the rotor sheave until the rotor knives have made one full revolution.
If there are interferences, correct them before proceeding to the next step.
Replace the drive guard.
REVISION 9/04 BJF
53
OPERATION
SECTION 5-2
Initial Startup
CHECK THE MOTOR ROTATION DIRECTION
Unlock the power.
Push the start-stop pushbutton in quick succession to start the machine then let it coast
without power.
While the machine is coasting to a stop, check the V-belt direction by looking through the
slots in the drive guard. The top of the V-belt should move toward the front of the machine as
indicated by the arrow plate on top of the guard cover.
If the motor rotation is not in the proper direction, TURN OFF AND LOCK OUT the
power per OSHA 1910.147 or ANSI Z244.1-1982 (Lockout/Tag-out of Energy Sources).
Call a qualified electrician to correct the problem. Refer to Section 3 for procedure.
RUN THE MOTOR
If the motor is turning in the proper direction, restart the machine with the start pushbutton
on the electrical cabinet and allow the motor to run up to speed for 30 seconds.
The granulator is now ready for operation
DISCHARGE AIR ADJUSTMENT
If the discharge airflow is insufficient, the granulator can accumulate in the discharge transition just
below the screen cradle. The buildup eventually backs up into the cutting chamber where continued
agitation by the rotor can cause overheating and possibly stalling of the motor.
REVISION 9/04 BJF
54
OPERATION
SECTION 5-3
Initial Startup
DISCHARGE AIR ADJUSTMENT
The discharge damper is located on the discharge transition. The damper controls the amount of
air that flows through the discharge transition and the discharge blower. Adjust it to obtain the
required discharge conveying velocity, while maintaining maximum airflow through the cutting
chamber.
REVISION 9/04 BJF
55
OPERATION
SECTION 5-4
Normal Operation
Never reach beyond the hopper curtain while the machine is running.
To clear a jam, refer to the procedure for clearing a jammed cutting chamber in Section
1. Avoid excessive feed rates. Feed the machine by placing the plastic pieces into the
hopper at a rate approximating the rated capacity of the granulator. Feed rates in excess
of rated capacity will cause the machine to stall.
SHUT DOWN THE MACHINE
To shut down, stop feeding the material into the hopper, and allow the machine
to run long enough to clear all material from the cutting chamber and discharge
chute.
Press the stop pushbutton on the electrical cabinet. This shuts off the drive
motor.
Turn off the power at the electrical cabinet.
DO NOT reach into the discharge cleanout opening with any part of your body.
Movement of the screen cradle at such a time could result in serious injury.
REVISION 9/04 BJF
56
MAINTENANCE
SECTION 6
Periodic Maintenance
TABLE 1: Periodic Maintenance Schedule
CHECK
DAILY WEEKLY MONTHLY
Check tightness of the upper chamber hold down handles.
Refer to Section 6, Cutting Chamber Access
X
Check tightness of the screen chamber wedges.
Refer to Section 6, Screen Replacement
X
Check infeed flap position/condition.
Refer to Section 6, Periodic Maintenance
X
Check the interlock actuator switch screws.
Position/condition. Refer to Section 6, Screen
replacement/Cutting Chamber Access
X
X
Do housekeeping around work area.
Check that the pivot pins and locknuts for jackscrews are
tight. Refer to Section 6, Periodic Maintenance
X
Inspect overall condition of jackscrews.
Refer to Section 6, Periodic Maintenance
X
Check the knife clearance and wear.
Refer to Section 4, Adjusting and Replacing Rotor Knives
X
Check that the rotor and bed knife bolts have proper
torque. Refer to Section 4, Adjusting and Replacing Rotor
Knives and Adjusting and Replacing The Bed Knives
Lubrication: More frequent lubrication may be required.
Refer to Section 6, Periodic Maintenance and Lubrication
Belt tension: Refer to Section 4, Settings and Adjustments
X
REVISION 9/04 BJF
X
X
57
MAINTENANCE
SECTION 6-2
LUBRICATION
Motor lubrication: check the tag from the motor manufacturer.
Main rotor bearings are lubricated at the factory but need re-lubrication periodically.
Grease fittings are provided for re-lubrication and are located on the right and left-hand
bearing housings. Lubricate every month or 750 hours, while the machine is running,
with approximately 84 grams (3 oz.) of grease. Use a lithium-based grease conforming
to NLGI grade #1. More frequent lubrication may be required in severe applications.
KNIFE SCREW TORQUE
Weekly, check the torque on the knife hold-down screws for both the rotor and the bed
knives. Refer to Section 4, Settings and Adjustments, for torque specs.
BELT TENSION
During the initial run-in period, check the belt tension at least two times in the first two
days of operation. After the initial run-in period check the belt tension on the drive
monthly. Refer to the subsection entitled Drive Belt Replacement and Adjustment in
Section 4, Settings and Adjustments.
SCREEN CONDITION
Inspect the screen monthly for wear and cracks. Check the holes in the screen
for elongation.
Turn the screens front-to-back monthly to even out the wear.
Refer to the instructions later in this section for screen access information.
REVISION 9/04 BJF
58
MAINTENANCE
SECTION 6-3
INFEED FLAP CONDITION
Daily, check the overall condition of the (3) infeed flaps, at the hopper inlet.
Check for wear, or tears in the flap, or if pieces are missing.
Replace them if you see damage.
Check the rods that support the flaps: they should be in good condition and in proper
location.
Any flap and/or its mounting hardware that is deteriorated should be replaced to
assure proper machine performance and operation.
REVISION 9/04 BJF
59
MAINTENANCE
SECTION 6-4
Screen Replacement
WORK SAFELY
OPEN THE SCREEN CRADLE
INTERLOCK
Disengage the Interlock actuator screw
by turning the knob at the center of the
chute assembly counterclockwise.
Make sure the end of the actuator
REMOVE THE DISCHARGE
Unscrew the knobs holding the right & left side discharge chutes.
Remove each chute by pulling them out toward the front of the machine.
REVISION 9/04 BJF
60
MAINTENANCE
SECTION 6-4
Screen Replacement
LOWER THE SCREEN CRADLE
WARNING!
The screen cradle sections are held in place
with wedge type retainers at the front of the
machine.
Gas springs are also used to assist in pivoting
the cradle assembly.
RETRACT THE SCREEN CRADLE
RETAINERS
Turn the screen cradle retainer knobs
clockwise until they stop. (This retracts the support
wedges from beneath the screen cradle).
When the wedges are fully retracted, rods
extend so that their ends are flush with the surface
of each of the retaining knobs mounting plates.
Push down on the bar handle to pivot the
cradle, exposing the screens.
BEWARE OF ROTOR KNIVES
CAUTION!
Avoid contact with the rotor knives, which are just above the screen. The cutting edges are very sharp.
Wear gloves to avoid injury when working in this area.
REVISION 9/04 BJF
61
MAINTENANCE
SECTION 6-5
Screen Replacement
REMOVE THE SCREEN
The screen is divided into segments. Remove one
segment at-a-time.
Grasp the screen on its near edge and raise the edge by
allowing the screen to slide in the cradle.
Pull it toward you slowly allowing it to slide over the
edge of the screen cradle and then let it down as you
continue to pull it toward you. Be careful not to hit the
rotor knives with the trailing end of the screen.
Ease it to the floor and remove it from the front of the
granulator.
Repeat the foregoing steps for each segment of the screen.
REPLACE THE SCREEN
Place the screen on the floor close to, and in front of
the machine. Set it on its circular surface with its long
dimension parallel with the machine.
Align one edge with the edge of the machine cradle.
Roll the screen into the cradle on the near side and then
slide it until it fits into the cradle.
REVISION 9/04 BJF
62
MAINTENANCE
SECTION 6-5
Screen Replacement
REPLACE THE SCREEN (Continued from previous page)
Guide the screen carefully as you "roll" it into the cradle,
then slide it down around the cradle until you can hang the
front lip of the screen over the front edge of the cradle.
Be careful not to hit the rotor knives with the far end of the
screen.
Repeat the foregoing steps for each segment of the screen.
RAISE THE SCREEN CRADLE
WARNING!
Make sure the screens fit properly to the cradle.
Pivot each cradle section up in place and start to turn in at least on cradle retainer for that section.
CLOSE THE SCREEN CRADLE RETAINERS
Turn the screen cradle retainer knobs counterclockwise
until they stop. (This returns the retainer wedges to their
positions under the screen cradle where they lock the cradle in
place.)
REVISION 9/04 BJF
63
MAINTENANCE
SECTION 6-5
Cutting Chamber Access
CLOSE THE SCREEN CRADLE
INTERLOCK
Engage the interlock screw by turning
it clockwise with a box wrench or a ratchet
wrench.
Make sure the interlock actuator screw
is fully seated against the top surface of its
housing.
When engaged, the interlock switch
closes the electrical control circuit to the
machine and allows it to operate.
REVISION 9/04 BJF
64
MAINTENANCE
SECTION 6-7
WORK SAFELY
WARNING!
INTERLOCK
Disengage the interlock actuator screw with a
box wrench or a ratchet wrench.
Swing the hold-down clamps toward you until they are disengaged from the cutting chamber housing.
REVISION 9/04 BJF
65
MAINTENANCE
SECTION 6-7
WARNING!
The jackscrew, which opens the machine, should never be operated until the rotor is
completely stopped.
Make sure no one is near the jackscrew or hopper during operation.
Turn the jackscrew crank handle until the hopper opens sufficiently to allow access to the
cutting chamber and the weight of the hopper is over the pivot center.
*NOTE: 50” & 62” machines are equipped with a hydraulic system to open the hopper.
WARNING!
Make sure no one is near the jackscrew or hopper.
Clear the mating surfaces of the cutting chamber of any debris that may prevent tight
closure.
Check the rotor locking mechanism & back out the plunger if necessary.
At the jackscrew, turn the crank handle until the hopper stops.
REVISION 9/04 BJF
66
MAINTENANCE
SECTION 6-8
Raise the hold-down clamps to their upright
positions.
Turn the knobs clockwise until they are
tight against the chamber housing.
wrench.
When engaged, the interlock closes the electrical control circuit to the motor and allows the machine
to run.
Start the granulator by depressing the start push button on the electrical cabinet.
REVISION 9/04 BJF
67
MAINTENANCE
SECTION 6-9
Knife Sharpening
BED KNIFE SHARPENING
Each bed knife is provided with two cutting edges. When the exposed edges become blunt, the knives can be
turned over and repositioned to present the new cutting edges.
It is not necessary to grind bed knives to the closely matched tolerance of the rotor knives and as with the rotor
knives, small nicks in the cutting edges will not seriously affect knife cutting efficiency. Bed knives smaller
than the minimum dimension shown must be replaced along with their fasteners.
It is important to note that the minimum dimensions given for the rotor knife and bed knife cannot be
combined simultaneously to produce a cutting combination. The grinding charts shown below and on the
previous page indicate the rotor knife and bed knife combinations that will work for each type of rotor knife.
**EXAMPLE: A 55° land rotor knife with a 3.937 inch " A " dimension will work only with bed knives
having an "E" dimension of .940 or more.
*NOTE: Replacement knife sets and knife re-sharpening services are available from Cumberland
Engineering. Contact the customer services department at 508-399-6400 or 800-229-2919.
REVISION 9/04 BJF
68
MAINTENANCE
SECTION 6-10
Knife Sharpening
ROTOR KNIFE SHARPENING (Steep Angle Configuration)
The rotor knives must be sharpened to within 0.003" (0.076 mm) of each other. Greater dimensional
variations prevent the proper setting of the knife gap and may create other serious complications.
Grinding the cutting edge until it is free of nicks can be wasteful. It is not harmful to allow small
nicks to remain in the cutting edge.
WARNING!
Do not install rotor knives, which are smaller than the minimum dimension shown because the
fasteners, which secure these knives will interfere with the cutting circle. The rotor will not be able
to rotate and the bed knives will be damaged.
It is important to note that the minimum dimensions given for the rotor knife and bed knife
cannot be combined simultaneously to produce a cutting combination. The grinding charts shown
below and on the following page indicate the rotor knife and bed knife combinations that will work
for each type of rotor knife.
**EXAMPLE: A keen edge rotor knife with 3.901inch " A " dimension will work only with bed
knives which have "D" dimensions of .940 inch or greater.
*NOTE: Replacement knife sets and knife re-sharpening services are available from Cumberland
Engineering. Contact the Customer Service Department at 508-399-6400 or 800-229-2919.
REVISION 9/04 BJF
69
TROUBLESHOOTING
SECTION 7-1
OVERVIEW
This section is intended to serve as a guide in checking possible problems that may
occur with the operation of your granulator.
SAFETY
The most important ingredient in any machinery operation is a constant adherence to
sound safety practices. The best way to assure safety in any activity that involves
troubleshooting or repairing the granulator is to retain complete control of the machine.
TURN OFF AND LOCK OUT THE POWER per OSHA 1910.147 OR ANSI
Z244.1-1982 (Lockout/ Tag-out of Energy Sources). If this is not possible, have an
electrician remove the fuses.
LOCATING TROUBLE
When you are correcting malfunctions, it is recommended that you check the associated
circuitry, and assemblies to ensure that there are no other defective devices. This
practice assures that a premature replacement of a part does not result in a repeat of the
malfunction and possible damage to the new part. Refer to the wiring diagrams and
schematics for information about these parts. Full size assembly drawings and wiring
diagrams specific to your unit are usually included with the manual but under separate
cover.
Locating mechanical problems, should they occur, is relatively straightforward. When
necessary, refer to Section 8, Parts Lists and Drawings.
TEST EQUIPMENT
The use of quality test equipment cannot be over-emphasized when troubleshooting is
required. Secure a good ammeter, one with a capacity of at least twice the AC and DC
current that can be encountered in the machine. Use a voltmeter that has a minimum
impedance of 5,000 ohms per volt on the AC scale and 20,000 ohms per volt on the DC
scale. Popular combination meters, VOM and VTM, can provide the necessary
functions.
TROUBLESHOOTING CHART
Troubleshooting procedures are listed in the table that follows. The first column lists the
apparent problem or symptom, the second column contains the probable cause, and the
suggested remedy is listed in the third column.
REVISION 9/04 BJF
70
TROUBLESHOOTING
SECTION 7-2
PROBLEM
PROBABLE CAUSE
REMEDY
-Processing FaultsA.) Material building up below
screen.
B.) Stalling
1.) Pneumatic discharge blower is
not running.
1.) Start the blower.
2.) Damper on discharge blower
not open enough.
2.) Adjust the damper on opposite
side of the machine from blower.
3.) Discharge line is blocked.
3.) Open line and remove
blockage.
1.) Overfeeding.
1.) Reduce feed rate.
2.) Partial or complete screen
blockage.
2.) Remove screen, clear and
inspect for any damage.
3.) Insufficient tension on V-Belt
drive, slipping and burning.
3.) Check belt tension and adjust
as necessary.
4.) Badly blunted or damaged
knives.
4.) Install re-sharpened or new
blades as required.
5.) Knife gap setting is too wide.
5.) Check the knife gap
clearances and adjust as required.
6.) Installation fault, motor is
running in reverse direction.
6.) Check the directional arrow
and reset electrical connections to
give correct rotational direction.
7.) Tighten safety interlock
actuator screw.
7.) Safety interlock is inoperative.
C.) Material overheating
1.) Check items 1,2,4,5 & 6 under
“Stalling.”
1.) Follow remedies listed for
each item.
2.) Screen size is too small.
Increase the screen size.
3.) When feeding sheet material,
the bed knife shield on rotor
down strike is incorrectly set.
3.) Check the bed knife projection
beyond the shield. Set it to 1/32”
(0.80mm) for film and 1/16”
(1.6mm) for thicker materials.
4.) Increase talc percentage rate
of feed.
When granulating rubber,
insufficient talc causing freshly
cut surfaces to re-adhere.
5.) Blockage in pneumatic
discharge line.
REVISION 9/04 BJF
5.) Check the direction of blower
rotation. Check venturi and
line/or transition piece for
blockage.
71
TROUBLESHOOTING
SECTION 7-3
PROBLEM
-Mechanical FaultsA.) Bearing overheating.
PROBABLE CAUSE
1.) Excessive tension on the VBelt drive.
as necessary.
2.) Inadequate lubrication.
2.) Check lubrication frequency
and the recommended lubricants
in motor and rotor bearings.
3.) Eliminate source of
contamination.
3.) Dirt/Contamination in
bearing.
B.) Visible cracks in knives.
C.) Knives moving on seats.
D.) Knives breaking.
E.) Excessive knife wear.
REMEDY
1.) Incorrect grinding procedure
or incorrect grinding wheels in
use.
1.) Uneven knife seat surface.
Check grinding procedures and
contact a Cumberland Service
Engineer.
1.) Clean knife seats to provide
maximum bearing surface.
2.) Loose knife screws.
2.) Tighten to correct torque per
section 4.
3.) Stretched knife screws.
3.) Knife screw should not be
used more than six times. Renew
them if there is evidence of
stretching.
1.) Refer to problem B, “Visible
cracks in knives”. (Above)
1.) Possibly due to cracks caused
by incorrect grinding.
2.) Abnormally heavy materials.
2.) Contact a Cumberland Service
Engineer.
3.) Contaminated input material.
3.) Inspect material from
contaminates/foreign matter.
1.) Open knife setting.
1.) Reset as detailed in section 4.
2.) Abrasive materials.
2.) Contact a Cumberland Service
Engineer for alternate material.
F.) See Copy.
REVISION 9/04 BJF
72
TROUBLESHOOTING
SECTION 7-4
PROBLEM
PROBABLE CAUSE
REMEDY
-Electrical FaultsA.) Motor fails to start.
B.) Motor starts, but will not take
loads.
C.) Motor starts when
disconnected from load, but not
when connected.
REVISION 9/04 BJF
1.) Power supply failure.
1.) Check fuses.
2.) Starter is inoperative.
2.) Check supply mains. Also
check the starter contacts for
burning, replace in necessary.
3.) Starter overloads cut out.
3.) Check the current
requirements on the motor
nameplate.
4.) Safety interlock is inoperative.
4.) Check and adjust as
necessary.
1.) Too much belt tension.
as necessary. Refer to Section 4.
2.) Motor is improperly wired.
2.) Check terminal connection
with the manufacturer’s
connection diagram located in the
conduit box and adjust as
necessary.
3.) Defective starter winding.
Check current in each phase with
an ammeter. If there is marked
difference in any one phase,
contact the motor manufacturer.
1.) Worn bearings.
1.) Check and replace if
necessary, in accordance with the
manufacturer’s literature.
73
PARTS LIST AND DRAWINGS
SECTION 8-1
Recommended Spare Parts
2000 SERIES GARNULATOR
TABLE 1: Recommended Spare Parts
Model
2042
2050
2062
Item
Qty.
Qty.
Qty.
6/10
6/10
6/10
HCHC
4
4
4
HCHC
24/48
-
36/60
*Property class 10.9M20 x 50 MM
Bed Knife Washer
20
-
28
*Property class 10.9M20 x 90 MM
Screen
20
-
28
Hardened
Rotor Bearing
2
2
3
Mild Steel 3/8” Diameter hole- standard
Drive Belt
2
2
2
130 MM Bore
6
-
-
5VX1500 –
Quantity for standard 75 hp drive
-
8
-
5VX1500 –
-
-
8
5VX1500 –
8
8
8
Push Screws
Rotor Knife (Depending on rotor)
Bed Knife
Rotor Knife Screw (See Copy)
Adjusting Screw – Bed Knife
Material
*NOTES: Din No. 961-10
When ordering spare parts, please have the model and serial number on hand.
Please call one of the following locations:
Cumberland Engineering-So. Attleboro, MA - - 508-399-6400
West Coast Service Center-Ontario, CA - - 909-390-8140/8141
Central Service Center-Kansas City, KA - - 913-780-0215
REVISION 9/04 BJF
74
PARTS LIST AND DRAWINGS
SECTION 8-2
Parts Identification Drawing No. CI044035
MODEL
2042
2050
2062
ITEM #
Qty.
Qty.
Qty.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
1
1
1
1
2
1
1
1
20
20
44
44
26
12
1
1
2
2
4
12
12
3
3
3
3
6
2
1
1
1
16
16
16
1
2
4
4
4
4
16
2
2
1
1
1
1
1
1
2
1
1
1
44
44
26
12
1
1
2
2
2
1
1
2
1
16
2
2
1
1
1
1
1
1
2
1
1
1
28
28
44
44
26
12
1
1
2
2
6
18
18
4
4
4
4
8
2
1
1
2
18
18
18
1
3
6
6
6
6
16
2
2
1
1
REVISION 9/04 BJF
MATERIAL
LH end plate
RH end plate
Down stroke knife block
Up stroke knife block
Up stroke knife clamp
LH down stroke knife shield
RH down stroke knife shield
Upper chamber
M20 bed knife washers
M20 Hex HD. screw Gr. 10.9
Plain washer M20
Lock washer M20
Dowel pin
Pivot pin
Pivot pin
Retainer bar
Cradle wedge assembly
M8 hex nut
Eye bolt M24 THD
Handle
Flat washer
Dowel pin 20 MM
Dowel pin 40 MM
Bearing housing
Cradle assembly
Bearing cap
Discharge interlock assembly
Plain washer M12
Lock washer M12
Hex HD screw M12
Jackscrew assembly/Hydraulic assembly
Gas spring bracket
Gas spring
Plain washer M8
Hex nut M8
Chamber MTG block
Hex HD screw M20
Spherical rotor bearing
Retaining ring
Chamber interlock assembly
Rotor assembly
75
Assembly Cutting Chamber Front View Drawing No.CI044035
SECTION 8-3
REVISION 9/04 BJF
76
Assembly Cutting Chamber Side View Drawing No.CI044035
SECTION 8-4
REVISION 9/04 BJF
77
Assembly Cutting Chamber Drawing No.CI044035
SECTION 8-5
REVISION 9/04 BJF
78
VCS Steep Angle 3 Knife Rotor Drawing No.CI044035
SECTION 8-6
REVISION 9/04 BJF
79
Rotor Positioning/Locking Assembly Drawing No.CI044115
SECTION 8-7
REVISION 9/04 BJF
80
GA Non Sound Enclosed Cumberland Drawing No.CI044063
SECTION 8-7
REVISION 9/04 BJF
81
GA Non Sound Enclosed Hyd Opening Cumberland Drawing
No.CI044063-1
SECTION 8-8
REVISION 9/04 BJF
82
GA Non Sound Enclosed Conveyor Feed Cumberland Drawing
No.CI044122
SECTION 8-9
REVISION 9/04 BJF
83
Motor horsepower
Voltage
Time delay fuses
50
50
50
50
50
60
60
60
60
60
75
75
75
75
75
100
100
100
100
100
125
125
125
125
125
150
150
150
150
150
200
200
200
200
200
250
250
250
250
250
300
300
300
300
300
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
200
208
230
460
575
300A
250A
250A
125A
100A
350A
300A
300A
150A
125A
400A
400A
350A
175A
150A
500A
500A
500A
225A
200A
600A
600A
500A
300A
225A
800A
800A
700A
350A
300A
1000A
1000A
800A
450A
350A
1200A
1200A
1200A
500A
400A
1500A
1500A
1200A
650A
500A
Circuit
breaker
Auto
trans
400A
400A
350A
175A
150A
450A
450A
400A
200A
175A
600A
500A
500A
250A
200A
800A
700A
600A
350A
250A
800A
800A
800A
400A
300A
1200A
1000A
1000A
500A
400A
1400A
1400A
1200A
600A
500A
2000A
2000A
1600A
800A
600A
2000A
2000A
2000A
1000A
800A
Circuit breaker
Across the line
Motor circuit
protection
Amp rating
Motor circuit
protection
Trip range
400A
400A
350A
175A
150A
450A
450A
400A
200A
175A
600A
500A
500A
250A
200A
800A
700A
600A
350A
250A
800A
800A
800A
400A
300A
1200A
1000A
1000A
500A
400A
1400A
1400A
1200A
600A
500A
2000A
2000A
1600A
800A
600A
2000A
2000A
2000A
1000A
800A
400A
400A
250A
100A
100A
400A
400A
400A
150A
100A
Not recommended
Not recommended
Not recommended
250A
150A
Not recommended
Not recommended
Not recommended
400A
150A
Not recommended
Not recommended
Not recommended
400A
400A
Not recommended
Not recommended
Not recommended
400A
400A
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
875-1750A
875-1750A
625-1250A
300-1000A
300-1000A
875-1750A
875-1750A
875-1750A
450-1550A
300-1000A
Not recommended
Not recommended
Not recommended
500-1000A
450-1550A
Not recommended
Not recommended
Not recommended
625-1250A
450-1550A
Not recommended
Not recommended
Not recommended
875-1750A
625-1250A
Not recommended
Not recommended
Not recommended
1000-2000A
625-1250A
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
Not recommended
RECOMMENDED GRANULATOR MOTOR BRANCH CIRCUIT
PROTECTION PER THE 1996 NEC CODE BOOK RULES
FOR STANDARD EFFICIENCY MOTORS*
(NEMA DESIGN B, C & D)
REVISION 9/04 BJF
84
Regrind Chart 10 Series – Steep Angle Cumberland Drawing
No.CI044141
REVISION 9/04 BJF
85
METRIC KNIFE BOLT/SCREW TIGHTENING TORQUE SPECIFICATIONS
FOR GRADE 10.9 FINE THREADS, UNLUBRICATED CONDITIONS
SCREW SIZE
M8
M10
M12
M14
M16
M18
M20
M24
LBS./FT.
28
54
100
155
232
340
472
810
NM.
38
73
135
210
315
460
640
860
APPLICABLE MODELS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
6X8
8X12 (ALL MODELS)
4X6
12X12 (ALL MODELS)
12X15 (ALL MODELS)
284
384
484
584
684
1426I
18X24
REVISION 9/04 BJF
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
18X36
X700
X1000
X1400
1456
1462
12X6 MARATHON
12X8 MARATHON
12X12 MARATHON
12X16 MARATHON
30T
56T
86
CUMBERLAND ENGINEERING
100 RODDY AVENUE
SOUTH ATTLEBORO, MA 02703-7951 USA
TEL: 1-508-399-6400
FAX: 1-508-399-6653
PARTS AND SERVICE
TEL: 1-800-299-2919
FAX: 1-508-399-6306
REVISION 9/04 BJF
87

2000 Series Manual

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